hydror™ disc brake - sram.com · disc brake pad advancement procedure notice do not apply dot...

GEN0000000005217 Rev E© 2019 SRAM, LLC

s e r v i c em a n u a l

HydroR™ Disc BrakeCaliper/Master Piston/Hose Replacement

SRAM® LLC WARRANTYEXTENT OF LIMITED WARRANTYExcept as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase. This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM makes no other warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of reasonable care, merchantibility, or fitness for a particular purpose) are hereby disclaimed.

LOCAL LAWThis warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from state to state (USA), from province to province (Canada), and from country to country elsewhere in the world.

To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modified to be consistent with such law, under such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United States of America, as well as some governments outside of the United States (including provinces in Canada) may:

a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer (e.g. United Kingdom).

b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.

For Australian customers:This SRAM limited warranty is provided in Australia by SRAM LLC, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, USA. To make a warranty claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6 Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in making the warranty claim are your responsibility. The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

LIMITATIONS OF LIABILITYTo the extent allowed by local law, except for the obligations specifically set forth in this warranty statement, in no event shall SRAM or its third party suppliers be liable for direct, indirect, special, incidental, or consequential damages.

LIMITATIONS OF WARRANTYThis warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com.

This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design.

This warranty does not apply when the product has been modified, including, but not limited to any attempt to open or repair any electronic and electronic related components, including the motor, controller, battery packs, wiring harnesses, switches, and chargers.

This warranty does not apply when the serial number or production code has been deliberately altered, defaced or removed.

This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service according to SRAM recommendations and/or riding or installation in conditions or applications other than recommended.

Wear and tear parts are identified as:

Dust sealsBushingsAir sealing o-ringsGlide ringsRubber moving partsFoam ringsRear shock mounting hardware and main sealsUpper tubes (stanchions)

Stripped threads/bolts (aluminium, titanium, magnesium or steel)Brake sleevesBrake padsChainsSprocketsCassettesShifter and brake cables (inner and outer)

Handlebar gripsShifter gripsJockey wheelsDisc brake rotorsWheel braking surfacesBottomout padsBearingsBearing racesPawls

Transmission gearsSpokesFree hubsAero bar padsCorrosionToolsMotorsBatteries

Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper charger, improper maintenance, or such other misuse.

This warranty shall not cover damages caused by the use of parts of different manufacturers.

This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM components.

This warranty shall not cover damages resulting from commercial (rental) use.

SAFETY FIRST!We care about YOU. Please, always wear your safety glasses

and protective gloves when servicing SRAM® products. Protect yourself! Wear your safety gear!

TABLE OF CONTENTSSRAM® HYDROR™ BRAKE SYSTEMS ................................................................................................................................................................5

TROUBLESHOOTING ..........................................................................................................................................................................................6DISC BRAKE PAD ADVANCEMENT PROCEDURE .................................................................................................................................................................................6

SRAM® HYDROR™ BRAKE CALIPER SERVICE ................................................................................................................................................8PARTS, TOOLS, AND SUPPLIES ..................................................................................................................................................................................................................8EXPLODED VIEW ..............................................................................................................................................................................................................................................8CALIPER BRAKE PAD REMOVAL .................................................................................................................................................................................................................9CALIPER PISTON REMOVAL ....................................................................................................................................................................................................................... 10CALIPER PISTON INSTALLATION ............................................................................................................................................................................................................. 12

SRAM® HYDROR™ LEVER SERVICE ................................................................................................................................................................16PARTS, TOOLS, AND SUPPLIES ................................................................................................................................................................................................................ 16EXPLODED VIEW ............................................................................................................................................................................................................................................ 16MASTER CYLINDER PISTON REMOVAL ................................................................................................................................................................................................. 17MASTER CYLINDER PISTON INSTALLATION ....................................................................................................................................................................................... 22

SRAM® HYDRAULIC HOSE REPLACEMENT ................................................................................................................................................ 26PARTS, TOOLS, AND SUPPLIES ............................................................................................................................................................................................................... 26EXPLODED VIEW ........................................................................................................................................................................................................................................... 27HOSE REMOVAL ............................................................................................................................................................................................................................................ 28HOSE INSTALLATION ................................................................................................................................................................................................................................... 31

5SRAM® HydroR™ Brake Systems

S R A M ® H y d r o R ™ B r a k e S y s t e m sWe recommend that you have your SRAM HydroR components serviced by a qualified bicycle mechanic. Servicing SRAM components requires knowledge of bicycle mechanics as well as the special tools and lubricants/fluids used for service.

SRAM brake systems need to be serviced periodically to optimize braking function. If brake fluid is leaking from any area of the brake there may be damage or wear and tear to the internal moving parts. If the system has been contaminated with the wrong fluid there may be damage to all rubber and plastic internal parts. If your brake was damaged in a crash there may be damage to the lever blade, pushrod, and housing assemblies. Inspect and replace these parts to restore proper brake function.

Visit www.sram.com/service for the latest SRAM Spare Parts catalog and technical information. For order information, please contact your local SRAM® distributor or dealer.

For recycling and environmental compliance information, please visit www.sram.com.

Information contained in this publication is subject to change at any time without prior notice. Your product's appearance may differ from the pictures contained in this publication.

SAFETY INSTRUCTIONSDo not use mineral oil or DOT 5 fluid.

If the brake system has been contaminated with mineral oil or DOT 5 fluid, flush all of the parts with soapy water, rinse them with clean water, then allow all the parts to dry prior to rebuilding. Install new seals, a new bladder, and replace the hose.

For best results, use only SRAM High-Performance DOT 5.1 brake fluid. If SRAM brake fluid is not available, only use DOT 5.1 or 4 brake fluid.

Use only DOT compatible grease.

Always wear safety glasses and nitrile gloves when working with DOT brake fluid.

Used DOT brake fluid should be recycled or disposed of in accordance to local and federal regulations.

Never pour DOT brake fluid down a sewage or drainage system or into the ground or a body of water.

Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be replaced.

Place an oil pan on the floor underneath the area where you will be working on the brake.

Servicing your brakes removes all of the brake fluid from the system. You must bleed your brakes after you service the brake caliper. Consult the HydroR Hose Shortening and Bleed Manual at www.sram.com/service.

NOTICEBefore beginning service, thoroughly clean the exterior of the product to avoid contamination of internal sealing part surfaces.

DOT brake fluids will damage painted surfaces. If any fluid comes in contact with a painted surface (e.g. your frame) or printing on the brakes, wipe it off immediately and clean it with isopropyl alcohol or water. Damage to painted and/or printed surfaces by DOT brake fluid is not covered under warranty.

When using a crowfoot socket and torque wrench, install the crowfoot socket at 90 degrees to the torque wrench.

http://www.sram.com/service

http://www.sram.com

6Troubleshooting

T r o u b l e s h o o t i n g

D i s c B r a k e P a d A d v a n c e m e n t P r o c e d u r e

NOTICEDo not apply DOT brake fluid or grease to caliper pistons when performing troubleshooting procedures. Use of DOT brake fluid or grease can diminish braking performance and cause rotor rubbing.

If your brakes exhibit excessive lever throw or spongy feel, perform the following steps before bleeding the system:

1. Clamp the bicycle into a bicycle work stand.

2. Remove the wheel from the affected caliper.n

3. Remove the brake pads.

4. Install the pad spacer.

5. Squeeze the brake lever several times until the pistons have advanced and contact the pad spacer. One piston may move faster than the other; continue to squeeze the lever until the pistons touch the spacer.

6. Remove the pad spacer.

7. Use a plastic tire lever to push the pistons back into the caliper bores.

8. Repeat steps 4-7 until the pistons move freely.

9. Install the brake pads and the wheel.

10. Loosen the caliper bolts.

11. Lightly squeeze (approx. 4 lbs) the brake lever several times to position the brake pads to the proper distance from the rotor.

12. Center the caliper on the rotor, and tighten the caliper bolts.

13. Spin the wheel and check the brake function. The pistons should move freely and there should not be excessive brake lever throw. If there is no improvement in the brake function, proceed with caliper service.

7SRAM® HydroR™ Brake Caliper Service

S R A M ® H y d r o R ™ B r a k e C a l i p e r S e r v i c e

P a r t s , T o o l s , a n d S u p p l i e s

Parts

• HRD B1 Caliper Parts Kit

Safety and Protection Supplies

• Apron

• Clean, lint-free rags

• Nitrile gloves

• Oil pan

• Safety glasses

Lubricants and Fluids

• Isopropyl alcohol

• SRAM DOT 5.1 hydraulic brake fluid

• SRAM DOT assembly grease

SRAM Tools

• SRAM bleed block hydraulic road disc

Bicycle Tools

• Bicycle work stand

Common Tools

• Air compressor with rubber-tipped air chuck nozzle

• Bench vise with aluminum soft jaws

• Crowfoot wrench: 8 mm, 9 mm

• Digital caliper

• Flare nut wrench: 8 mm

• Hex wrench: 2.5 mm

• Hex bit socket: 2.5 mm

• Needle nose pliers

• Open end wrench: 6 mm, 10 mm

• Pick

• T25 TORX® wrench

• T25 TORX bit socket

• Torque wrench

E x p l o d e d V i e w

Banjo

Piston seal(s)

Banjo bolt

Caliper body

Brake pads

Piston bore(s)

Pad retention bolt

E-clip

Body bolt

Caliper piston(s)

O-ring(s)

8Caliper Brake Pad Removal

C a l i p e r B r a k e P a d R e m o v a lRemove the caliper mounting hardware from the caliper, then set them aside in the order that they were removed.

Flat mount: Leave the mounting bracket installed.

Remove the E-clip from the pad retention bolt.

Remove the pad retention bolt from the caliper.

Remove the brake pads.

NOTICEBrake pads must be replaced if the total thickness of the backing plate and pad friction material is less than 3 mm.

1

2

Needle nose pliers

2.5 mm

3

Digital caliper

9Caliper Piston Removal

C a l i p e r P i s t o n R e m o v a l

NOTICEDOT brake fluid will damage painted surfaces. If any fluid comes in contact with a painted surface (e.g. your frame) or printing on the brakes, wipe it off immediately and clean it with isopropyl alcohol or water. Damage to painted and/or printed surfaces by DOT brake fluid is not covered under warranty.

Disconnect the hose from the banjo.

NOTICEFluid will drip. Place an oil pan and/or rag under the hose.

Install the caliper into the soft jaws of a vise. Remove the banjo bolt. Set the banjo aside.

Remove the caliper body bolt.

Separate the caliper body halves.

1

6 and 9 mm Connectamajig™

8 and 10 mm Flat and Post mount

8 mm Post Mount

T25 Flat Mount2

T25 Post Mount

T25 Flat Mount3

4

10Caliper Piston Removal

Remove the caliper o-ring.

Place each caliper half, piston side down, on a soft rubber mat or a small section of inner tube on a flat surface.

Firmly press a rubber-tipped air chuck nozzle into the banjo port to dislodge the piston from the caliper.

⚠CAUTION - EYE HAZARDWear safety glasses. The caliper piston may dislodge rapidly from the caliper, which can lead to bodily injury or damage to the parts. Point the caliper piston toward a rubber surface to prevent the piston from becoming a projectile.

Remove the piston seal from each caliper body half.

⚠CAUTIONDo not scratch the seal gland with the pick. Scratches could cause fluid to leak when the brake is applied, which will contaminate the brake pads and could lead to a brake failure.

Spray isopropyl alcohol inside each piston bore, the inside and the outside of the caliper, and clean them with a rag.

NOTICEIf the brake system has been contaminated with mineral oil or DOT 5 fluid, flush all of the parts with soapy water, rinse them with clean water, then allow all the parts to dry prior to rebuilding. Install new seals, a new bladder, and replace the hose.

For the best braking performance, use only SRAM® DOT 5.1 brake fluid. If SRAM fluid is not available, use only DOT 5.1 brake fluid or 4 fluid.

Pick Post Mount

Pick Flat Mount5

Rubber-tipped air chuck nozzle

6

7

8

11Caliper Piston Installation

C a l i p e r P i s t o n I n s t a l l a t i o n


Apply a small amount of SRAM® 5.1 DOT brake fluid to a new piston seal and install a seal into the piston bore on each caliper body half.

Inspect the caliper pistons for damage and replace the pistons if necessary.

Apply a small amount of SRAM 5.1 DOT brake fluid to the circumference of each piston. Install a caliper piston into the piston bore on each caliper body halve.

NOTICEFor the best braking performance, use only SRAM High-Performance 5.1 DOT brake fluid. If SRAM fluid is not available, use only DOT 5.1 or 4 brake fluid. Do not use grease. Grease will prevent the pistons from fully retracting into the caliper bores which will reduce braking performance.

Apply grease to the new o-ring and install it onto the outboard caliper half.

NOTICEThe o-ring must be fully seated in the groove to prevent pinching the o-ring during assembly. A pinched o-ring may cause a leak.

Align the caliper body halves. Install the body bolt into the caliper two full turns.

NOTICEVisually inspect the banjo bolt hole to confirm the o-ring is not pinched or protruding. If the o-ring is visible, then remove the bolt and repeat steps 3 and 4. Pinched o-rings may cause leaks.

5.1 DOT brake fluid

1

2

5.1 DOT brake fluid

SRAM DOT assembly grease

3

T25 Post Mount

T25 Flat Mount4


Tighten the caliper body bolt.

Post mount only: Remove the banjo bolt o-ring. Apply grease to the new o-ring and install it on the bolt. Install the bolt into the caliper.

Flat mount only: Remove the o-rings from the banjo bolt. Apply grease to the new o-rings and install them on the banjo bolt so one is on each side of the banjo fitting.

5

T25 9.8-11.8 N·m (86-104 in-lb) Post and Flat

6

DOT grease Post Mount

Post Mount

DOT grease Flat Mount

Flat Mount


Tighten the banjo bolt.

Spray isopropyl alcohol on the caliper body and clean it with a rag.

Insert the bleed block into the caliper. Install the pad retention bolt.

Cut the hose to install a new barb and compression fitting.

NOTICEYou must install a new hose barb and compression fitting before reconnecting the brake lever to the hose.

7

9.8-11.8 N·m (86-104 in-lb) 8 mm

9.8-11.8 N·m (86-104 in-lb) T25

Post Mount

Flat Mount8

9

2.5 mm Bleed block

10

SRAM Hydraulic Hose Cutter 2.7 - 3.2 N·m (24-28 in-lbs) 22 mm


Apply grease to the threads on a new hose barb. Thread the hose barb into the hose until it is flush with the end of the hose.

NOTICEDo not overtighten the hose barb. Overtightening may cause damage to the hose liner.

Install the banjo boot and compression nut onto the hose. Thread a new compression fitting over the hose barb, counter-clockwise, until it is flush or slightly lower than the hose barb.

Apply grease to the outside of the compression fitting and the threads of the compression nut.

Install the hose firmly into the brake caliper while threading the compression nut by hand. Tighten the compression nut.

⚠CAUTIONServicing your brake caliper removes fluid from the system. You must bleed the brakes before reinstalling the brake pads. Installing the brake pads prior to bleeding the brakes could contaminate the brake pads and lead to a brake failure. For brake bleed and brake pad replacement instructions, consult the HydroR™ Hose Shortening and Bleed Manual at www.sram.com/service.

T8 DOT grease

11

DOT grease

8 and 10 mm 8 N·m (71 in-lb) Post and Flat mount

6 and 9 mm 2-2.5 N·m (17.4-21.7 in-lb) Connectamajig™

12

15SRAM® HydroR™ Lever Service

S R A M ® H y d r o R ™ L e v e r S e r v i c ePerform this service if you have forward or backward play, or rattling in your lever.

Prior to servicing the lever, record the lever placement on the bars and position of the reach so you can return the product to these settings. For an externally routed hose, detach the hose from the bicycle frame according to the bicycle manufacturer's instructions. For an internally routed hose, disconnect the hose from the caliper before removing the hose from the frame.

P a r t s , T o o l s , a n d S u p p l i e sParts

• HRD/HRR Shift Lever Pushrod Assembly


• Apron


• Nitrile gloves

• Oil pan

• Safety glasses



• SRAM DOT 5.1 hydraulic brake fluid


SRAM Tools

• SRAM brake bleed syringe

Bicycle Tools


Common Tools

• Flat blade screwdriver

• Hex wrenches: 2.5, 5 mm

• Hex bit sockets: 2.5, 5 mm


• Phillips #2 screwdriver

• Pick

• Pin removal punch: 2 mm x 1.5 in

• Rubber mallet

• Torque wrench


HoodMaster Piston assembly

Shifter blade (shift-brake models only)

Thread formingscrew

Lever blade

Inner pivot barrel

Outerpivot barrel(shift-brake models only)

Lever bias spring

Roll pin(gen. 2)

Circlip

Pivot Pin

Reach adjust pushrod

Stop plate gen. 1

Stop plate gen. 2

Hood cover

16Master Cylinder Piston Removal

M a s t e r C y l i n d e r P i s t o n R e m o v a l


There are two stop plate types for HydroR disc brakes: stop plate generation 1, and stop plate generation 2. Follow the procedure for the stop plate type in your lever assembly.

Remove the shifter cable from the derailleur cable anchor points according to the user manual on www.sram.com/service, if applicable.

Remove the handlebar tape. Loosen the handlebar clamp and remove the brake lever from the bicycle.

Remove the hood cover.

Use a pick to remove the circlip from the lever pivot pin.

Stop plate gen. 1

Stop plate gen. 2

5 mm

1

2

3

Pick Brake lever

Pick Shift brake lever


Push the pivot pin out of the lever blade. Remove the lever bias spring.

⚠WARNING- EYE HAZARDWear safety glasses. The lever bias spring may eject from the lever.

Turn the reach adjust pushrod clockwise to release the pivot barrel(s) and lever blade from the hood. Use your hand to hold the shifter blade out of the way on shift-brake models.

Set the lever blade assembly aside.

Fill a clean bleed syringe with 5-10 ml of DOT 5.1 brake fluid.

Remove the bleed screw from the bleed port.

4

Small hex wrench

5

2.5 mm Shift-brake lever

2.5 mm Brake lever

6

DOT 5.1 brake fluid 5-10 ml

7

T10 TORX®


Thread the bleed syringe into the bleed port.

Fluid may drip from the bleed port. Clean the brake assembly with water and a shop towel to remove any DOT brake fluid that drips from the bleed port.

Stop Plate Gen. 1: Remove the thread forming screw from the stop plate in the hood.

Remove the stop plate and reach adjust pushrod.

8

9

Phillips #2 Stop plate gen. 1

Pick

Pick


Stop Plate Gen. 2: Use a mallet and a pin-removal punch to gently tap out the roll pin.

Remove the thread forming screw from the stop plate in the hood, then remove the stop plate and reach adjust pushrod.

Place a shop towel over the master piston, and apply light pressure to the piston. This will prevent the piston from rapidly ejecting from the brake assembly.

Apply gentle pressure to the bleed syringe until the master piston protrudes from the bore far enough to be grabbed with your fingers.

Pull the master piston out of the bore by hand.

Pin removal punch Mallet

Roll pin

Phillips #2

Pick

10

Master piston

Shop towel

11


Use a shop towel to remove excessive DOT brake fluid from the brake assembly.

Unthread the bleed syringe from the bleed port.

NOTICEPlace a shop towel below the brake assembly to catch any spilled DOT brake fluid. Clean DOT brake fluid from all painted surfaces.

Install the bleed screw into the bleed port.

Spray isopropyl alcohol onto a shop towel and clean the brake assembly.

12

13

Shop towel

T10 1.5-1.7 N·m

14

Isopropyl alcohol

Shop towel

21Master Cylinder Piston Installation

M a s t e r C y l i n d e r P i s t o n I n s t a l l a t i o nApply grease to the piston seal and o-rings on a new master cylinder piston assembly.

Install the spring onto the white spring capture on the master cylinder shaft.

Install the master cylinder assembly.

Install the reach adjust pushrod through the stop plate. Use your hand to hold the shifter blade out of the way on shift-brake models.

1

DOT grease

2

Stop plate gen. 1

Stop plate gen. 23


Stop Plate Gen 1: Use a 2.5 mm hex wrench to depress the reach adjust pushrod so it pushes against the master cylinder piston head and use a pick to seat the piston stop plate underneath the bar in the hood.

Tighten the thread forming screw into the stop plate while holding the reach adjust pushrod in place.

Stop Plate Gen. 2: Tighten the thread forming screw into the stop plate.

Insert the roll pin into the roll pin hole, then gently tap the roll pin through the stop plate and the hood. Use the pin removal punch to make sure the roll pin is centered in the hood.

Phillips #2 2.0-2.5 N·m (17-22 in-lb) 2.5 mm

4

2.5 mm Stop plate gen. 1


Phillips #2 2.0-2.5 N·m (17-22 in-lb)


Stop plate gen. 2


Shift-brake lever: Install the inner pivot barrel into the outer pivot barrel in the lever so the holes in the pivot barrels align with the reach adjust pushrod in the hood.

Brake lever: Install the inner pivot barrel into the lever so the hole in the pivot barrel aligns with the reach adjust pushrod in the hood.

Thread the reach adjust pushrod into the pivot barrel counter-clockwise.

Install the pivot pin into the inset hole on the hood and through the lever blade hole so that the pin protrudes slightly.

Orient the lever bias spring with the long arm of the spring against the brake lever.

Use needle nose pliers to hold the spring into place so you can push the pivot pin through the lever bias spring and through the other hole in the hood.

Shift-brake lever

2.5 mm Shift-brake lever

2.5 mm Brake lever

2.5 mm Brake lever

5

Needle nose pliers6


Use needle nose pliers or a flat blade screwdriver to install the circlip onto the pivot pin with the rounded side facing outward.

NOTICEInspect the circlip to make sure it is installed properly. If the circlip is missing or not installed properly, it could cause the pivot pin to fall out of the brake.

Spray isopropyl alcohol on the brake and clean it with a rag.

Replace the shifter cable, if needed.

Install the hood cover.

Flat blade screwdriver or pliers

Flat blade screwdriver or pliers7

8

9

10

25SRAM® Hydraulic Hose Replacement

Tighten the brake lever onto the handlebar in the previous recorded position. Return the reach adjust to its original position. Route the hose through or onto the frame according to the frame manufacturer's instructions. Install the shifter cable to the derailleur according to the user manual at www.sram.com/service.

⚠CAUTIONServicing your shift-brake or brake lever removes fluid from the system, you must bleed the brakes. For brake bleed and brake pad replacement instructions, consult the HydroR™ Hose Shortening and Bleed Manual at www.sram.com/service.

S R A M ® H y d r a u l i c H o s e R e p l a c e m e n tPerform the hose replacement service if the hose needs to be replaced. For hose shortening instructions, consult the HydroR™ Hose Shortening and Bleed Manual at www.sram.com/service.

P a r t s , T o o l s , a n d S u p p l i e sParts

• SRAM road disc brake hydraulic hose kit


• Apron


• Nitrile gloves

• Oil pan

• Safety glasses




SRAM Tools

• Bleed block hydraulic road disc

• SRAM hydraulic hose cutter tool

Bicycle Tools


Common Tools

• Crowfoot wrench: 8 mm, 9 mm

• Digital caliper

• Flare nut wrench: 8 mm

• Hex wrenches: 2.5 mm, 4 mm, 5 mm

• Hex bit sockets: 2.5 mm, 4 mm, 5 mm

• Marker


• Open end wrench: 6 mm, 10 mm

• Phillips #1 screwdriver

• Pick

• Torque wrench

• TORX® wrenches: T8, T10, T25

• TORX bit socket: T10, T25

11

5 mm 6-8 N·m (52-70 in-lb)

26Exploded View


Hood cover

Compressionnut

Hydraulic hose

Banjo

BootCompression fitting and Hose barb

Reservoir cover and bolts

Bladder Banjo bolt

Banjo

O-ring Hood

Hatch cover and screws

27Hose Removal

H o s e R e m o v a l

Remove the wheel from the bicycle according to the manufacturer's instructions.

Remove the E-clip from the pad retention bolt.

Remove the pad retention bolt from the caliper.

Remove the brake pads.

NOTICEBrake pads must be replaced if the total thickness of the backing plate and pad friction material is less than 3 mm.

Insert the bleed block into the caliper, then install the pad retention bolt.

1

2

Needle nose pliers

2.5 mm

3

Digital Caliper

2.5 mm

4

28Hose Removal

Cut the hose and remove the compression nut and banjo boot.

Remove the hose from the bicycle frame according to the bicycle manufacturer's instructions.

Disconnect the hose from the banjo.

NOTICEFluid will drip. Place an oil pan and/or rag under the hose.

Remove the shifter cable from the derailleur cable anchor points according to the user manual on www.sram.com/service, if applicable.

Hydraulic hose cutter

8 and 10 mm5

6

5 mm

29Hose Removal

Remove the handlebar tape. Loosen the handlebar clamp and remove the brake lever from the bicycle.

Remove the hood cover from the hood.

Replace the shifter cable, if needed.

Remove the three hatch cover screws. Remove the hatch cover.

7

8

9

Phillips #1

Phillips #1

30Hose Removal

Remove the four reservoir cover bolts.

Use a rag to remove the reservoir cover and bladder assembly. Discard the fluid into an oil pan.

Remove the banjo bolt and discard the hose.

10

T10

11

12

4 mm

31Hose Installation

H o s e I n s t a l l a t i o nSpray isopropyl alcohol on the reservoir, bladder, and reservoir cover and clean them with a rag. Install the bladder onto the reservoir cover.

NOTICEIf the brake system has been contaminated with mineral oil or DOT 5 fluid, flush all of the parts with soapy water, rinse them with clean water, then allow all the parts to dry prior to rebuilding. Install new seals, a new bladder, and replace the hose.

Apply grease to the new o-rings and install them onto both sides of the new banjo.

Install the banjo and hose into the hood.

Align the bladder assembly in the reservoir cover with the reservoir in the hood.

1

DOT grease

DOT grease2

3

4 mm 3.9-4.4 N·m (35-39 in-lb)

4

32Hose Installation

Install the four reservoir cover bolts at an alternating sequence until a torque of 1.3-1.5 N·m (11-13 in-lb) is achieved.

Install the hatch cover onto the hood. Tighten the three hatch cover screws.

Spray isopropyl alcohol on the hood and clean it with a rag.

Install the hood cover onto the hood.

5

T10 1.3-1.5 N·m (11-13 in-lb)

Phillips #1 0.1 N·m (1 in-lb)

Phillips #1 0.1 N·m (1 in-lb)6

7

8

33Hose Installation

Install the brake lever onto the handlebar in the desired position and tighten.

Route the new hose through or onto the frame according to the frame manufacturer's instructions. Install the shifter cable to the derailleur(s) according to the user manual at www.sram.com/service.

To shorten the hose, hold the hose at the caliper with a length that creates a gentle bend in the hose and allows the handlebar to freely turn from side to side.

Mark your cut location, then cut the hose.

Apply grease to the hose barb threads. Thread the hose barb into the hose until it is flush with the end of the hose.

NOTICEDo not overtighten the hose barb. Overtightening may cause damage to the hose liner.

Install the banjo boot and compression nut onto the hose.

9

5 mm 6-8 N·m (52-70 in-lb)

10

11

Marker

Hydraulic hose cutter

T8 DOT grease

T812

13

34Hose Installation

Thread the compression fitting over the hose barb, counter-clockwise, until it is flush or slightly lower than the hose barb.

The compression fitting is reverse threaded.

Apply grease to the outside of the compression fitting and the threads of the compression nut.

Connectamajig™ only: Calipers with a Connectamajig at the banjo must replace the banjo when replacing the hose.

The caliper can be removed or remain installed on the frame or fork.

Remove the Connectamajig banjo. Apply grease to the new banjo bolt o-ring(s) and install on the bolt. Install the bolt into the caliper and tighten the new banjo.

DOT grease14

DOT grease Flat Mount

Flat Mount

T25 9.8-11.8 N·m (86-104 in-lb) Flat Mount

8 mm 9.8-11.8 N·m (86-104 in-lb) Post Mount

8 mm Connectamajig

DOT grease15

35Hose Installation

Install the hose firmly into the brake caliper while threading the compression nut by hand. Tighten the compression nut.

Install the banjo boot over the compression nut.

⚠CAUTIONReplacing the hose removes all of the fluid from the system. You must bleed the brakes before reinstalling the brake pads. Installing the brake pads prior to bleeding the brakes could contaminate the brake pads and lead to a brake failure. For brake bleed and brake pad replacement instructions, visit www.sram.com/service.

16

10 mm 5-6 N·m (44-52 in-lb) 8 mm

17

This publication includes trademarks and registered trademarks of the following companies:

TORX® is a registered trademark of Acument Intellectual Properties, LLC

www.sram.com

ASIAN HEADQUARTERS SRAM Taiwan No. 1598-8 Chung Shan Road Shen Kang Hsiang, Taichung City Taiwan R.O.C.

WORLD HEADQUARTERS SRAM LLC

1000 W. Fulton Market, 4th Floor Chicago, Illinois 60607

USA

EUROPEAN HEADQUARTERS SRAM Europe

Paasbosweg 14-16 3862ZS Nijkerk

The Netherlands

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